KLINGER KHD-SGF Gebrauchsanweisung

IOM-KHD-SGF-111_V1.4_EN

Installation, Operation,

& Maintenance Manual

V-Notch Segment Ball Valve

KHD-SGF

IOM-KHD-SGF-111_V1.4_EN

V-Notch Segment Ball Valve

KHD-SGF

Table of Contents

I Introduction

1.1 Contact Information

1.2 General Notes

1.3 Precautions and Warnings

1.4 Storage

II Installation

2.1 General Notes

2.2 Installation of Wafer Ends

2.3 Pneumatic and Electrical Connections

III Operation

3.1 Handling

3.2 Cleaning

3.3 Manual Operation

3.4 Remote Operation

3.5 Techinical Data

IV Maintenance

4.1 General Notes

4.2 Maintenance Frequency

4.3 Disassembly

4.4 Reassembly

4.5 Troubleshooting

4.6 Technical Data and Product Information

IOM-KHD-SGF-111_V1.4_EN

V-Notch Segment Ball Valve

KHD-SGF

Chapter I

Introduction

The manual is provided to ensure proper installa-

tion, operation & maintenance for KHD-SGF, the

Wafer Type and Flanged V-notch Segment Ball Valve

with metal seat and soft seat, manufactured and

supplied by KLINGER DIE ERSTE INDUSTRY CO., LTD.

The valves are identified by marking on the body or

on a name plate or both.

1.1 Contact Information

For information concerning warranties, or for ques-

tions pertaining to installation, operation or mainte-

nance of KLINGER Die Erste products, contact:

KLINGER DIE ERSTE INDUSTRY CO., LTD.

5F-1, No.936, Sec. 4, Wen-Xin Road,

Taichung City, Taiwan 406

Phone: +886 4 22310059

Fax: +886 4 22360236

Email: [email protected]

To order replacement parts, contact KLINGER Die

Erste sales at address listed above.

1.2 General Notes

The following instructions refer to KLINGER Die Er-

ste Wafer Type and Flanged V-notch Segment Ball

Valve with soft seat and metal seat as described in

the KLINGER Die Erste current catalog.

Keep the protective covers in place until the valve is

ready for installation. Valve performance depends

upon prevention of damage to ball surface. After re-

moving the cover make sure that the valve is com-

pletely open and free of obstructions, dirt, particles

or any materials that may cause seat or seal dam-

age.

Valves may contain a silicon-based lubricant for

transportation, which aids in the assembly of the

valve. Lubricant may be removed with a solvent if

found objectionable. Alternatively valves can be or-

dered free of lubricants upon request.

Certain ferrous valves contain phosphate material,

and are oil dipped during the course of manufac-

ture. However, the processes used are completely

non-toxic.

1.3 Precautions and Warnings

Choose the correct material of valve for different

applications before obtaining the valve. The user

should be aware of the operating situation, fluid

properties, and the possible outcomes when imple-

menting valves into the pipeline system. KLINGER

Die Erste suggests that the user should make esti-

mation beforehand.

Fluid undergoes property changes with respect

to outside factors, particularly fluid left inside the

sealed cavity. When temperature and pressure ex-

ceed allowable value, valve failure may occur. User

should be aware of that excessive pressure and

temperature at nearby pipeline system can also

cause valve failure as well.

Wafer Type and Flanged V-notch Segment Ball

Valves are generally recommended for throttling

services as well as on-off functions.

Do not touch the valve surface when high tempera-

ture fluid is flowing through the valve.

Do not attempt to open the bonnet and the cap

during operation, especially with the presence of

high pressure in the pipeline system.

For safety concern, unstable fluid should not be

used in the pipeline system, unless otherwise spec-

ified with the category III in Declaration of conformi-

ty.

NOTE:

1. KHD-SGF Wafer Type and Flanged V-notch Seg-

ment Valves are installed between flanges. The

body is in one part; the shaft and segment ball are

separated.

2. The valve is either soft or metal seated. De-

pending on customers' requirement, the structure

of the supplied valve may be different.

3. The valve is designed for both control and shut-

off applications.

4. Actuators and accessories are only discussed

briefly. Please refer to individual manuals for fur-

ther information on their IOM manuals.

CAUTION:

Before removing valve from pipeline, operator

should be aware of that: media flowing through

the valve may be corrosive, toxic, flammable, or

of a contaminant nature. Where there is evidence

of harmful fluids having flowed through the valve,

the utmost care must be taken. It is suggested

IOM-KHD-SGF-111_V1.4_EN

V-Notch Segment Ball Valve

KHD-SGF

Chapter II

Installation

Flush the pipeline carefully before installing the

valve. The particles of dirt or debris or welding may

damage the segment sealing surface and seats.

Also, before installing, check all valve and mating

flanges to ensure gasket surfaces are free from de-

fects.

2.1 General Notes

1) Direction

The valves are designed with a preferred flow di-

rection. Install the valve according to the direction

marked on the valve body. Valve installed with re-

versed flow direction will not seal properly.

Figure 2.1 Flow Direction Indication

In the case of valve automation with actuators, in-

stall the valves with the actuator at or above the

centerline of the horizontal piping, as shown in Fig-

ure 2.1.

CAUTION:

Do not fasten supports to the flange bolting or the

actuator.

NOTE:

User should avoid installing the valve so that the

shaft point downwards because impurities travel-

ing in the pipeline may enter the body cavity and

damage the gland packing.

1.4 Storage

If the valves are not to be installed immediately,

please store the valve carefully before installation,

preferably indoors in a dry and clean place.

Also, the valve ports should be sealed by plastic

caps to prevent dirt from entering and damaging in-

ner parts.

Note:

1. The valve is delivered in the closed position. Be-

fore storing, check to see that the valve is in the

CLOSED position in order to avoid damage to the

seal.

2. The surface of the valves should be greased

properly for protection.

that the following safety precautions should be

taken when handling valves.

1) Always wear eye shields.

2) Always wear eye shields.

3) Always wear gloves and footwear.

4) Wear protective headgear.

5) Ensure that running water is readily accessible.

6) Fire extinguisher must be obtainable if media is

flammable.

Check the line gauge to ensure that no pressure is

present at the valve. Ensuring media is released by

operating valve slowly to the half open position.

Ideally, the valve should be decontaminated when

the ball is in the half open position.

These valves, when installed, have body connectors

which form an integral part of the pipeline and the

valve cannot be removed from the pipeline without

being dismantled- see DISMANTLING section for

reference.

CAUTION:

Do not exceed the valve performance limitation.

CAUTION:

Before installing, make sure the line pressure has

been relieved, and any hazardous fluids have been

drained or purged from the system.

IOM-KHD-SGF-111_V1.4_EN

V-Notch Segment Ball Valve

KHD-SGF

্্

Figure 2.2 Proper position while piping

NOTE:

When installing horizontally, the support of the ac-

tuator must be strengthened to avoid valve leak-

age caused by valve stem deflection.

2) Position

The body, cap and gasket are in the connection area

of ball valve and pipeline. The bear weight ability

and gradient are very important to the pipe instal-

lation. Do not make the pressure from the pipeline,

and stress to concentrate on the connecting area of

body and cap. Ball, seat, and stem will be damaged.

Consequently, deformation and leakage may occur.

3) Fittings

Select the correct size of fittings according to the

pipeline specification. Tighten the segment valve

to the pipeline adequately with appropriate bolts.

Do not attempt to correct pipeline misalignment by

means of flanged bolting.

4) Systems hydrostatic test

Before delivery, valves are tested 1.5 times the al-

lowable pressure at ambient temperature in open

position. However, after installation, the piping sys-

tem may subject to system tests, as condition not

to exceed the marking pressure.

5) Pre-Installation Wash

Before the valve installation, clean the pipeline sys-

tem to remove any foreign deposits by water. Clean

the connecting wafer end surfaces as well to ensure

tight sealing.

2.2 Installation of Ends

1) Wafer End

1. Verify valve is in the fully OPEN position.

2. Use the appropriate size bolt and heavy hex nut

(not included) as recommended for flange size

and class.

3. Do not over tighten the joints bolting.

4. Place gasket on each flange connection (not in-

cluded).

5. Follow gasket manufacturer’s recommended

practice for tightening flange bolts.

2) Flanged End

1. Before installing the valves, make sure the

flanges and the pipe are free from grit, dirt or

burrs.

2. The flanges must be aligned and parallel with

the correct distance to allow the valve face-to-

face dimension and gaskets to fit between.

3. Tighten the flange bolts in a crossover pattern,

with a torque values determined by the gasket

manufacturer, other variables like gasket type

and material, bolt, flange and lubricant affect the

IOM-KHD-SGF-111_V1.4_EN

V-Notch Segment Ball Valve

KHD-SGF

tightening torque values.

4. Note that the bolts tightening must be uniform

in order to create a parallel movement of the

two flanges and uniform deformation of the

gasket in between them.

2.3 Pneumatic and Electrical Connections

When installing the actuator, make sure that the

valve-actuator combination functions properly. The

valve OPEN and CLOSED position are indicated by a

groove at the top of valve shaft. See Figure 2.2.

FLOW

Figure 2.3 The top graph indicates an OPEN valve,

and the bottom one represents a CLOSED valve

If possible, install the valve so that the actuator can

be disconnected without removing the valve from

the piping.

Please refer to the appropriate instruction manual

shipped with the automation devices for the in-

stalled actuator, positioner, filter/regulator, solenoid,

and/or limit switches.

When making pneumatic connections, it is recom-

mended that PTFE tape or paste is used on thread-

ed joints, unless otherwise specified by the com-

ponents instruction manual. The pneumatic supply,

such as dry air or nitrogen, should be clean. When

making electrical connections, wiring of components

should be in accordance with any and all applicable

local and national codes and standards.

Before installing the actuator, use an adjustable

wrench to manually rotate the valve stem sever-

al times. This rotation breaks the torque that may

have built up during long-term storage.

NOTE:

When the valve is in a bare-stem state, be careful

not to rotate the valve ball OVER the FULLY OPEN

and FULLY CLOSED positions. Operation over the

positions may restrict the valve ball from returning

to the normal operation.

IOM-KHD-SGF-111_V1.4_EN

V-Notch Segment Ball Valve

KHD-SGF

Chapter III

Operation

For manual operation, shift the handle in clockwise

direction for CLOSED and counter-clockwise for

OPEN. If the handle is in parallel position with the

flow direction, the valve is OPEN. If the handle is

in right angle position with the flow direction, the

valve is CLOSED.

When installing actuator or the valve is operated

with removable handle, the user should ensure the

position of the valve whether open or close. The line

on the top of the stem indicates whether the valve

is in OPEN or in CLOSED position.

3.1 Handling

During the segment ball valve installation, it must

follow the procedure to handle at the both side of

the bodies. If using cable for big size valve, make

sure the cable must be strong enough to ensure the

safety during the installation.

Never lift the valve package by the actuator, posi-

tioner, limit switch or their piping. The Valve damage

or personal injury may occur from falling parts.

3.2 Cleaning

Even though the valves were transported under a

clean environment, operator must check if there

is any foreign body or dusts inside the bore. If

yes, clean the valve before installation. Operator

may clean the valves by water, compression air, or

steam. However, valve automation devices shall be

cleaned only with water or steam, using compres-

sion air to clean the valve automation devices is

strictly prohibited. For cleaning operation, first step

is put the valve bore perpendicular to the ground

and clean, ensure all the dusts are be removed from

the bore. The second step is to check and clean all

the connecting pipe bore and connection area. No

flush, rust and foreign bodies are allowed to avoid

the blocking and leakage.

3.3 Manual Operation

KLINGER Die Erste V-notch Segment Ball Valves

have ¼ turn operation opening in a counter-clock-

wise direction. When the handle is positioned across

the pipeline, this indicates that the valve is closed.

When the handle is positioned parallel with the

pipeline, this indicates the valve is open.

In cases where it is difficult to operate a manual

valve due to large torque requirements, it is recom-

mended to provide a gear operator for the valve.

The hand wheel on the gear box indicates the open-

ing and closing direction of the valve. Generally

speaking, the clockwise direction of the handwheel

is the closing direction, and the counterclockwise

direction is the valve opening direction. As shown in

Fig 3.2 below.

Figure 3.2 Handwheel Rotation Direction

for CLOSED and OPEN position of a gear box

NOTE:

Due to the spring structure, when manually oper-

ating the soft-seated segment ball valve, be sure

not to over-rotate the segment ball. Opening more

than 90 degrees may cause the segment ball to

deviate from the effective path of the spring, mak-

ing it impossible to use it normally.

3.4 Remote Operation

Where manual operation is not required valves may

be automated for remote operation, instrument

controls etc. KLINGER Die Erste offers a wide range

of pneumatic and electric actuators for different

working conditions.

When an actuator is used, no stop plate is fitted

to the valve since end stops are an integral part of

the actuator. Operation will be in accordance with

KLINGER Die Erste Installation, Operation and Main-

tenance Instructions for the relevant actuator.

IOM-KHD-SGF-111_V1.4_EN

V-Notch Segment Ball Valve

KHD-SGF

CAUTION:

Keep hands, other parts of the body, tool and oth-

er objects out of the open flow port. Leave no for-

eign object inside the pipeline. When the valve is

actuated, the ball segment act as a cutting device.

Also, the segment position may change when the

valve is moved. The failure may result in damage

or personal injury.

3.5 Technical Data

3.5.1 Pressure-Temeprature Chart

Temperature (°F)

Temperature (°C)

Pressure ( psig )

Pressure ( barg )

250

300

200

150

100

350

50 150 250 350 450 550 650 750 850

50 100 150 200 250 300 350 400 450

PTFE PACKING

KHD-SGF-CL150

GRAPHITE PACKING

Temperature (°F)

Temperature (°C)

Pressure ( psig )

Pressure ( barg )

250

300

200

150

100

350

50 150 250 350 450 550 650 750 850

50 100 150 200 250 300 350 400 450

KHD-SGF-PN16

PTFE PACKING

GRAPHITE PACKING

3.5.2 Flow Coefficients

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

VALVE STROKE

NORMALIZED FLOW COEFFICIENTS

DN NPS Max. Kv Max. Cv

DN25 1" 23 27

DN32 1-1/4" 40 46

DN40 1-1/2" 60 69

DN50 2" 94 109

DN65 2-1/2" 145 168

DN80 3" 240 277

DN100 4" 403 466

DN125 5" 600 694

DN150 6" 668 772

DN200 8" 1473 1703

DN250 10" 1800 2081

DN300 12" 3256 3764

DN350 14" 5515 6375

DN400 16" 7292 8430

IOM-KHD-SGF-111_V1.4_EN

V-Notch Segment Ball Valve

KHD-SGF

Chapter IV:

Maintenance

4.1 General Notes

Due to the nature of the control valve, the segment

ball valve has different maintenance requirements

than normal ball valves. When necessary, valves

may be refurbished using a minimal number of

components, and none of which require machining.

KLINGER Die Erste valves are designed for easy ser-

vice and assembly in the field.

The following aspects should, however, help to ex-

tend valve life.

CAUTION:

Do not dismantle the valve or remove it from the

pipeline while the valve is pressurized.

4.2 Maintenance Frequency

KLINGER Die Erste Segment Ball Valves must un-

dergo a scheduled inspection based on the appli-

cation. The maintenance frequency is determined

based upon the application of the valve. User should

consider the following factors when determining the

maintenance time interval: fluid type, flow velocity,

operation frequency, pressure, and temperature.

If the application requires intensive valve opening,

closing, and fine adjusting, then the valve should be

inspected frequently.

Note:

KLINGER Die Erste recommends inspecting the

valve at least every one (1) year.

Note:

Please use the original spare parts to ensure the

valve functions well.

Note:

When sending back the valve to KLINGER Die Er-

ste for investigation, do not disassemble it. Clean

the valve carefully and flush the valve internals. If

possible, inform us about the medium used in the

valve.

4.3 Disassembly

1. Valve shall be positioned vertically by resting

body side flanges on clean ground surface (pref-

erably covered with rubber sheet).

2. Turn the valve to CLOSED position.

3. Remove the handle, lever or gear box if applica-

ble.

4. Loosen the BRACKET BOLTS (15) and detach

the BRACKET (16) from the mounting pad of the

valve.

5. Loosen the bottom bolts and remove the TRUN-

NION CAP (5) and THRUST WAHSER (4) out of

the valve.

6. Loosen GLAND NUTS (19) evenly, remove

GLAND (17), and remove GLAND STUDS (18)

from mounting pad of the valve.

7. Put the downstream end of the valve upward

and lay it flat on the desktop

8. Remove the pins locking between SEGMENT

BALL (8), UPPER STEM (13) and LOWER SHAFT

(2) either by grinding or using a spindle. Detach

the pins (7) by drilling.

Note:

Be careful not to damage the original bores of the

pins.

9. Place the valve on the table with the down-

stream end up. Use a flat-blade screwdriver

and soft hammer to push the UPPER STEM (13)

away from the SEGMENT BALL (8).

10. Pull the UPPER STEM (13) and V-Ring STEM

PACKING (14) out of the valve from the stuffing

box.

11. Push the LOWER SHAFT (2) from the ball cavity

away and the lower end of valve. At this time,

the SEGMENT BALL (8) can be taken out from

the downstream port of the valve.

CAUTION:

For the soft-seal valve seat, since there are sever-

al compression springs between the inner wall of

the upstream end and the segment ball, it should

be noted that when the lower shaft is removed,

the segment ball may pop out of the valve body

and cause personal injury.

Note:

Please make sure that the Segment Ball (8) is not

going to fall out of the valve and been damaged.

IOM-KHD-SGF-111_V1.4_EN

V-Notch Segment Ball Valve

KHD-SGF

12. Inspect the Segment Ball (2) for any damages.

13. Put the upstream end of the valve up and lay

it flat on the table. Tap the METAL SEAT (10) or

SOFT SEAT RING (10A) on the upstream end of

the valve with a soft hammer to move it out of

the other end. Note that this step may cause

damage of the seat when it hits the tabletop.

Make sure that the tabletop is protected and

clean.

14. For metal-seated model, use a flat-blade screw-

driver to tick out SPRING (9); the upper and

lower BUSHINGS (3) can be hooked out to be re-

placed.

15. Replace the O-RING (11) on METAL SEAT (10) or

SOFT SEAT RING (10A) if necessary.

16. For soft-seated model, replace the SOFT SEAT

(10B) from the SOFT SEAT RING (10A).

17. Clean carefully and inspect all parts for wear

and damage. Make sure all gaskets and packing

residue is thoroughly cleaned before valve is re-

assembled. KLINGER Die Erste recommends all

sort parts should be replaced.

4.4 Reassembly

Before reassembly, inspect all the valve for any

damage on body and all internals.

Note:

Damaged internals to be replaced by KLINGER Die

Erste repair kits only.

1. Insert upper and lower BUSHINGS (3) from the

top of the stuffing box and the bottom of the

valve respectively.

2. Place O-RING (11) on the groove of SEAT (10)

and apply lubricating oil.

3. Put the downstream end of the valve upward

and lay it flat on the desktop.

4. For metal-seated model, put the MEAL SEAT

(10) with O-RING (11) into the valve cavity and

push it toward the upstream end for position-

ing. Put the SPRING (9) into the groove between

the SEAT (10) and the upstream end with nee-

dle-nose pliers.

5. For soft-seated model, put the SOFT SEAT RING

(10A) with compressed SPRINGS (9A), O-RING

(11) and SOFT SEAT (10B) into the valve cavity

and push it toward the upstream end for posi-

tioning.

6. Put the KEY (12) into UPPER STEM (13), and

check whether this KEY (12) is matching SEG-

MENT BALL (8), UPPER STEM (13). And lubricate

them.

7. Carefully insert the SEGMENT BALL (8) into the

valve cavity with the valve closed. At the same

time, push the UPPER STEM (13) with KEY (12)

from the stuffing box to match the valve stem

with SEGMENT BALL (8).

8. Push in the LOWER SHAFT (2) from the bottom,

tap the bottom of the valve stem lightly to align

the upper end of the LOWER STEM with the

lower hole plane inside the SEGMENT BALL, as

shown in the figure.

9. Tap the top of the UPPER STEM (13) to align the

bottom end with the upper hole plane inside the

SEGMENT BALL, as shown in the figure.

10. Lock the pins with UPPER STEM (13) and LOW-

ER SHAFT (2) to the SEGMENT BALL (8).

Note:

If the SEGMENT BALL (8) has been disassembled

by drilling before, please confirm the size of the pin

hole and use the corresponding PIN (7).

11. Put the inverted V-shaped PACKING (14) into the

stuffing box.

12. Screw the GLAND STUDS (18) into the valve

mounting flange. Install the GLAND (17) and fas-

ten the GLAND NUT (19).

13. Insert the TRUST WASHER (4) to the bottom of

the valve and install the TRUNNION CAP (5) with

the O-RING (6) with bolts.

14. Check that it is assembled correctly and in the

CLOSED position.

15. Install the BRACKET (20) to the valve with BOLTS

(15) and WASHER (16). Install the handle or au-

tomation devices if applicable.

Inhaltsverzeichnis

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